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Md Reza E Rabby

Md Reza E Rabby

Pacific Northwest National Laboratory
PO Box 999
Richland, WA 99352
(509) 372-6843

Biography

Dr. Md Reza-E-Rabby joined at PNNL in 2016 as a Post Doctorate Research Associate and assigned to the task of joining thick section dissimilar material. Following his graduate work at the University of South Carolina in 2015, Dr. Rabby started his career as a Friction Stir Weld (FSW) engineer in a company that provide canister for the nuclear spent fuel in power plants. His expertise in FSW tool design brought him in current position at PNNL for developing new solid state joining technology of dissimilar material such as, Al-steel, Al-Mg, Al/Mg-carbon/glass fiber reinforced polymer(C/G FRP) composites etc. over a range of stack up thicknesses of 1-75 mm. In addition, his research is also focused towards the investigation of solid phase processing of lightweight materials using Shear Assisted Processing and Extrusion (ShAPE™) for enhancing properties with novel microstructures, and the transition the technology from the lab scale manufacturing to the bulk production environment.

Research Interests

  • Developing design criteria for FSW tools
  • Solid phase processing and joining of materials (ShAPE™, FSW)
  • Structural analysis using finite element method (FEM)
  • Metallurgy of aluminum alloys and their metal matrix composites
  • Synthesis and characterization of nanocomposite materials
  • Vacuum assisted resin transfer molding (VARTM) for manufacturing C/G FRP

Education and Credentials

  • Ph.D. Mechanical Engineering, University of South Carolina, 2015
  • M.S. Mechanical Engineering, Tuskegee University, 2010
  • B.Sc. Civil Engineering, Bangladesh University of Engineering and Technology (BUET), 2006

Affiliations and Professional Service

  • The Minerals, Metals and Materials Society (TMS)

Awards and Recognitions

  • Outstanding Performance award, PNNL, 2016
  • Travel Grant Award, the Graduate School at University of South Carolina (2013-2014)

PNNL Patents

PNNL Publications

2024

  • Das H., M. Reza E Rabby, S.A. Whalen, P. Upadhyay, and G.J. Grant. 2024. "Impact of backing plate and thermal boundary conditions for high-speed friction stir welding of 25-mm thick aluminum alloy 7175-T79." International Journal of Precision Engineering and Manufacturing-Green Technology. PNNL-SA-184852. doi:10.1007/s40684-024-00607-x
  • Gwalani B., X. Li, A.K. Nittala, W. Choi, M. Reza E Rabby, J.D. Escobar, and A.J. Bhattacharjee, et al. 2024. "Unprecedented Electrical Performance of Friction-Extruded Copper-Graphene Composites." Materials & Design 237. PNNL-SA-190528. doi:10.1016/j.matdes.2023.112555
  • Li L., M. Pole, H. Das, S. Niverty, M. Reza E Rabby, J. Fernandez dos Santos, and A. Soulami. 2024. "Meshfree Process Modeling and Experimental Validation of Friction Riveting of Aluminum 5052 to Aluminum 6061." In Light Metals 2024: Proceedings of the Light Metals Symposium held at the TMS Annual Meeting and Exhibition, March 3-7, 2024, Orlando, FL, edited by S. Wagstaff, 298-305. PNNL-SA-189749. doi:10.1007/978-3-031-50308-5_39
  • Milligan B.K., M. Reza E Rabby, B.J. Schuessler, T.J. Roosendaal, T.L. Lemmon, and S.A. Whalen. 2024. "Microstructural Refinement of an Al-Ce-Mg Alloy via Shear Assisted Processing and Extrusion." Materials Science and Engineering A. Structural Materials: Properties, Microstructure and Processing 916, no. _:Art. No. 147328. PNNL-SA-202613. doi:10.1016/j.msea.2024.147328
  • Whalen S.A., M. Reza E Rabby, B.K. Milligan, B.J. Schuessler, T.J. Roosendaal, and T.L. Lemmon. 2024. Wrought Aluminum-Cerium Alloys by Shear Assisted Processing and Extrusion. PNNL-36591. Richland, WA: Pacific Northwest National Laboratory. Wrought Aluminum-Cerium Alloys by Shear Assisted Processing and Extrusion

2023

  • Das H., K.S. Kappagantula, A. Srivastava, P. Upadhyay, J. Fernandez dos Santos, and M. Reza E Rabby. 2023. "Embedded anchoring of multi-material assemblies by friction riveting process." In TMS 2023: Friction Stir Welding and Processing XII Symposium held at the TMS Annual Meeting and Exhibition, March 19-23, 2023. San Diego, CA. Minerals, Metals and Materials Series, edited by Y. Hovanksi, et al, 149-156. Cham:Springer. PNNL-SA-177374. doi:10.1007/978-3-031-22661-8_14
  • Das H., P. Upadhyay, M. Reza E Rabby, U. Okeke, and M. Mcdonnell. 2023. "High speed butt joining of 1” thick 2139-T8." In TMS 2023: Friction Stir Welding and Processing XII Symposium held at the TMS Annual Meeting and Exhibition, March 19-23, 2023. San Diego, CA. Minerals, Metals and Materials Series, edited by Y. Hovanksi, et al, 209-215. Cham:Springer. PNNL-SA-178259. doi:10.1007/978-3-031-22661-8_19
  • Reza E Rabby M., H. Das, T. Wang, M. Komarasamy, S.A. Whalen, and G.J. Grant. 2023. "High-Speed Friction Stir Butt Welding of 25.4 mm Thick 7175-T79 Aluminum Alloy." Manufacturing Letters 38. PNNL-SA-184859. doi:10.1016/j.mfglet.2023.08.140
  • Reza E Rabby M., X. Li, G.J. Grant, S.N. Mathaudhu, and A.P. Reynolds. 2023. "Process parameters and system responses in friction extrusion." Journal of Manufacturing Processes 85. PNNL-SA-166885. doi:10.1016/j.jmapro.2022.11.027
  • Srivastava A., H. Das, D. Ramirez Tamayo, L. Li, M. Pole, B. Gwalani, and A. Soulami, et al. 2023. "Extent of interlocking and metallurgical bonding in friction riveting of aluminum alloy to steel." International Journal of Advanced Manufacturing Technology 128, no. 7-8:2899-2911. PNNL-SA-180851. doi:10.1007/s00170-023-12111-8
  • Whalen S.A., B.S. Taysom, M. Reza E Rabby, N.R. Overman, and T.W. Skszek. 2023. Shear Assisted Processing and Extrusion (ShAPE) of Lightweight Automotive Components (CRADA 418). PNNL-33766. Richland, WA: Pacific Northwest National Laboratory. Shear Assisted Processing and Extrusion (ShAPE) of Lightweight Automotive Components (CRADA 418)
  • Whalen S.A., B.S. Taysom, N.R. Overman, M. Reza E Rabby, Y. Qiao, T. Richter, and T.W. Skszek, et al. 2023. "Porthole Die Extrusion of Aluminum 6063 Industrial Scrap by Shear Assisted Processing and Extrusion." Manufacturing Letters 36. PNNL-SA-179478. doi:10.1016/j.mfglet.2023.01.005
  • Whalen S.A., N.R. Overman, B.S. Taysom, M. Reza E Rabby, T.W. Skszek, and M. Diciano. 2023. "Shear Assisted Processing and Extrusion of Unhomogenized Aluminum Alloy 6063 Castings with High Iron Content." In Light Metals 2023: TMS Annual Meeting & Exhibition, edited by S. Broek, 327-332. PNNL-SA-177354. doi:10.1007/978-3-031-22532-1_45
  • Whalen S.A., N.R. Overman, B.S. Taysom, M.E. Bowden, M. Reza E Rabby, T.W. Skszek, and M. Diciano. 2023. "Effect of High Iron Content on Direct Recycling of Unhomogenized Aluminum 6063 Scrap by Shear Assisted Processing and Extrusion." Journal of Manufacturing Processes 97. PNNL-SA-181577. doi:10.1016/j.jmapro.2023.04.067

2022

  • Li L., M. Reza E Rabby, N.R. Overman, T. Wang, S.A. Whalen, G.J. Grant, and S.N. Mathaudhu, et al. 2022. "Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method." Materials & Design 221. PNNL-SA-173428. doi:10.1016/j.matdes.2022.111010
  • Li X., M. Reza E Rabby, A.D. Guzman, G.J. Grant, S.N. Mathaudhu, M. Hinton, and A.P. Reynolds. 2022. "Strain and strain rate in friction extrusion." Journal of Materials Research and Technology 20. PNNL-SA-170376. doi:10.1016/j.jmrt.2022.07.116
  • Reza E Rabby M., A. Srivastava, M. Pole, A.K. Nittala, B. Gwalani, and K.S. Kappagantula. 2022. Solid Phase Processing of Lead-Free Brass with Carbon Additives. PNNL-33415. Richland, WA: Pacific Northwest National Laboratory. Solid Phase Processing of Lead-Free Brass with Carbon Additives
  • Reza E Rabby M., T. Wang, N.L. Canfield, D.D. Graff, T.J. Roosendaal, and S.A. Whalen. 2022. "Effect of post-extrusion heat treatment on mechanical property of aluminum alloy 2024 tube produced using Shear Assisted Processing and Extrusion (ShAPE)." In Light Metals Symposium held at the TMS Annual Meeting and Exhibition (Light Metals 2022), February 27- March 3, 2022, Anaheim, CA, edited by D. Eskin, 301-307. Cham:Springer. PNNL-SA-166238. doi:10.1007/978-3-030-92529-1_42

2021

  • Li X., M. Reza E Rabby, M.E. Ryan, G.J. Grant, and A.P. Reynolds. 2021. "Evaluation of Orthogonal Strain Components in Friction Extrusion." Journal of Materials Research and Technology 15. PNNL-SA-157484. doi:10.1016/j.jmrt.2021.10.001
  • Nazaeri Tiji S., A. Asgharzadeh, T. Park, S.A. Whalen, M. Reza E Rabby, M. Eller, and F. Pourboghrat. 2021. "Microstructure and Mechanical Properties of the AA7075 Tube Fabricated using Shear Assisted Processing and Extrusion (ShAPE)." Archives of Civil and Mechanical Engineering 21, no. 2:44. PNNL-SA-155953. doi:10.1007/s43452-021-00179-6
  • Olszta M.J., N.R. Overman, M. Reza E Rabby, T.J. Roosendaal, M. Mcdonnell, and S.A. Whalen. 2021. "Joining AA7099 to Ni-Cr-Mo Steel Using Single Pass Friction Stir Dovetailing and AA6061 Butter Layer." JOM. The Journal of the Minerals, Metals and Materials Society 73, no. 7:2203-2211. PNNL-SA-155286. doi:10.1007/s11837-021-04668-0
  • Reynolds A.P., X. Li, M. Reza E Rabby, M. Komarasamy, and G.J. Grant. 2021. Discovering SPP Thermomechanical Pathways. PNNL-32133. Richland, WA: Pacific Northwest National Laboratory. Discovering SPP Thermomechanical Pathways
  • Reza E Rabby M., M.J. Olszta, N.R. Overman, M. Mcdonnell, and S.A. Whalen. 2021. "Friction Stir Dovetailing of AA7099 to Steel with AA6061 Interlayer for Reduced Zn Embrittlement at Dissimilar Interface." Journal of Manufacturing Processes 61. PNNL-SA-155326. doi:10.1016/j.jmapro.2020.10.084
  • Reza E Rabby M., T.J. Roosendaal, P. Upadhyay, N.R. Overman, J.A. Silverstein, M. Mcdonnell, and S.A. Whalen. 2021. "Process Robustness of Friction Stir Dovetailing of AA7099 to Steel with In Situ AA6061 Interlayer Linking." In Friction Stir Welding and Processing XI. The Minerals, Metals & Materials Series, edited by Y. Hovanski, et al. Cham:Springer. PNNL-SA-155938. doi:10.1007/978-3-030-65265-4_14
  • Taysom B.S., N.R. Overman, M.J. Olszta, M. Reza E Rabby, T. Skszek, M. Diciano, and S.A. Whalen. 2021. "Shear assisted processing and extrusion of enhanced strength aluminum." International Journal of Machine Tools and Manufacture 169. PNNL-SA-162162. doi:10.1016/j.ijmachtools.2021.103798
  • Taysom B.S., S.A. Whalen, M. Reza E Rabby, M. Diciano, and T. Skszek. 2021. "Shear Assisted Processing and Extrusion of Thin-Walled AA6063 Tubing." In Light Metals Symposium held at the TMS Annual Meeting and Exhibition, March 15-18, 2021. Minerals, Metals and Materials Series, edited by L. Perander, 6, 281 - 285. Cham:Springer. PNNL-SA-156007. doi:10.1007/978-3-030-65396-5_42
  • Whalen S.A., M. Reza E Rabby, T. Wang, X. Ma, T.J. Roosendaal, and B.S. Taysom. 2021. "Shear Assisted Processing and Extrusion of Aluminum Alloy 7075 Tubing at High Speed." In Light Metals held at the TMS Annual Meeting and Exhibition, March 15-18, 2021. Minerals, Metals and Materials Series, edited by L. Perander, 6, 277-280. Cham:Springer. PNNL-SA-156009. doi:10.1007/978-3-030-65396-5_41
  • Whalen S.A., M.J. Olszta, M. Reza E Rabby, T.J. Roosendaal, T. Wang, D.R. Herling, and B.S. Taysom, et al. 2021. "High Speed Manufacturing of Aluminum Alloy 7075 Tubing by Shear Assisted Processing and Extrusion (ShAPE)." Journal of Manufacturing Processes 71. PNNL-SA-164792. doi:10.1016/j.jmapro.2021.10.003

2020

  • Reza E Rabby M., K.A. Ross, M. Mcdonnell, and S.A. Whalen. 2020. "Numerical Simulation and Experimental Validation of Joint Performance in Aluminum-Steel Lap Welds Formed by Friction Stir Dovetailing." Journal of Materials Processing Technology 277. PNNL-SA-145070. doi:10.1016/j.jmatprotec.2019.116459
  • Wang T., P. Upadhyay, M. Reza E Rabby, X. Li, L. Li, A. Soulami, and K.S. Kappagantula, et al. 2020. "Joining of Thermoset Carbon Fiber Reinforced Polymer and AZ31 Magnesium Alloy Sheet Via Friction Stir Interlocking." International Journal of Advanced Manufacturing Technology 109, no. 3-4:689-698. PNNL-SA-149338. doi:10.1007/s00170-020-05717-9

2019

  • Reza E Rabby M., S.A. Whalen, K.A. Ross, and M. Mcdonnell. 2019. "Joining AA7099 to Ni-Cr-Mo Steel using Friction Stir Dovetailing." In Friction Stir Welding and Processing X, edited by Y Hovanksi, et al, 171-180. Cham:Springer. PNNL-SA-138056. doi:10.1007/978-3-030-05752-7_16
  • Ross K.A., M. Reza E Rabby, M. Mcdonnell, and S.A. Whalen. 2019. "Advances in Dissimilar Metals Joining through Temperature Control of Friction Stir Welding." MRS Bulletin 44, no. 8:613-618. PNNL-SA-144347. doi:10.1557/mrs.2019.181
  • Whalen S.A., M.J. Olszta, C. Roach, J.T. Darsell, D.D. Graff, M. Reza E Rabby, and T.J. Roosendaal, et al. 2019. "High Ductility Aluminum Alloy made from Powder by Friction Extrusion." Materialia 6. PNNL-SA-138614. doi:10.1016/j.mtla.2019.100260

2018

  • Reza E Rabby M., K.A. Ross, N.R. Overman, M.J. Olszta, M. Mcdonnell, and S.A. Whalen. 2018. "Joining Thick Section Aluminum to Steel with Suppressed FeAl Intermetallic Formation via Friction Stir Dovetailing." Scripta Materialia 148. PNNL-SA-131279. doi:10.1016/j.scriptamat.2018.01.026

2017

  • Reza E Rabby M., K.A. Ross, S.A. Whalen, Y. Hovanski, and M. Mcdonnell. 2017. "Solid-State Joining of Thick-Section Dissimilar Materials using a New Friction Stir Dovetailing (FSD) Process." In Friction Stir Welding and Processing IX, edited by Y Hovanksi, et al, 67-77. Cham:Springer International Publishing. PNNL-SA-119210. doi:10.1007/978-3-319-52383-5_8

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